Washing systems

ABSTRACT

A washing system includes a housing, a drain line, and a recirculation line. The housing receives, via a fluid inlet, fresh water during one or more wash cycles of a wash session. The drain line is coupled to the housing and includes a valve and is also configured to receive soiled water from the housing during the wash session. The recirculation line is coupled to and extends from the valve of the drain line and is configured to receive a portion of the soiled water via the valve. The recirculation line includes an integrated fluid sanitizer module configured to at least partially sanitize the portion of the soiled water, and the recirculation line is configured to deliver sanitized water from the integrated fluid sanitizer module to the fluid inlet of the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. National Stage of International ApplicationNo. PCT/US2017/046349, filed Aug. 10, 2017, which claims the benefit ofand priority to U.S. Provisional Application No. 62/373,191, filed Aug.10, 2016, each of which is hereby incorporated by reference herein inits entirety.

FIELD OF THE PRESENT DISCLOSURE

The present disclosure relates generally to washing systems, and moreparticularly, to washing systems including a recirculation line with anintegrated fluid sanitizer module.

BACKGROUND

In industrial laundry applications, tunnel washing systems are oftenused to clean large volumes of soiled laundry (e.g., clothes, linens,fabrics, or the like). Typically, soiled laundry is placed into aloading hopper of a wash tunnel and is then moved through a series ofzones or cycles, including a pre-wash zone, a main wash zone, and arinse zone. After the laundry exits the rinse zone, a press then removesexcess water from the laundry prior to moving the laundry to a dryer.Within each zone, chemicals and fresh water (collectively, “wash water”)is added to perform a desired cleaning operation. As the wash waterflows through each zone and contacts the soiled laundry, the wash watermay be contaminated by bacteria, viruses, algae, mold, fungi, or thelike from the soiled laundry. As a result, soiled wash water is thenremoved from each zone via a drain and exits the system as waste. In aneffort to reduce waste water, soiled wash water can be recirculatedwithin the washing system. However, recirculation of soiled wash waterleads to acceleration growth of bacteria, viruses, algae, mold, fungi,or the like in the wash water.

In addition, the pH of the wash water in each of the various zones mustbe controlled to effectively and efficiently clean the soiled laundry.For example, the pH of the wash water at the beginning of the main washzone can be about 10.5, while the pH of the wash water at the end of therinse zone can be between about 5 and 6. To achieve this difference inpH, chemicals are introduced into each of the zones or cycles to raiseor lower the pH as required. Continually adding these chemicals toachieve a desired pH level adds to the costs of operating the tunnelwashing system.

The present disclosure addresses these and other problems.

SUMMARY

According to some implementations of the present disclosure, a washingsystem includes a housing, a drain line, and a recirculation line. Thehousing is configured to receive, via a fluid inlet, fresh water duringone or more wash cycles of a wash session. The drain line is coupled tothe housing and includes a valve, and the drain line is configured toreceive soiled water from the housing during the wash session. Therecirculation line is coupled to and extends from the valve of the drainline and is configured to receive a portion of the soiled water via thevalve. The recirculation line includes an integrated fluid sanitizermodule configured to at least partially sanitize the portion of thesoiled water, and the recirculation line is configured to deliversanitized water from the integrated fluid sanitizer module to the fluidinlet of the housing.

According to some implementations of the present disclosure, a tunnelwashing system includes a housing, a press, and a recirculation line.The housing includes a pre-wash zone, a main wash zone, and a rinsezone. The main wash zone includes a first fluid inlet and a first fluidoutlet, and the rinse zone includes a second fluid inlet and a secondfluid outlet. The press is coupled to a press tank which is configuredto receive and store therein soiled press water. The recirculation lineis coupled to the press tank and is configured to receive a portion ofthe soiled press water. The recirculation line includes an integratedfluid sanitizer module configured to at least partially sanitize theportion of the soiled press water.

The above summary of the present disclosure is not intended to representeach embodiment, or every aspect, of the present disclosure. Additionalfeatures and benefits of the present disclosure are apparent from thedetailed description and figures set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a washing system according to someimplementations of the present disclosure;

FIG. 2 is a partial cross-sectional view of an integrated fluidsanitizer module of the tunnel washing system of FIG. 1 according tosome implementations of the present disclosure;

FIG. 3 is a schematic illustration of a tunnel washing system accordingto some implementations of the present disclosure;

FIG. 4A is a plot of the pH of pre-wash zone water, wash zone water,rinse zone water, and press water in a first washing system according tosome implementations of the present disclosure; and

FIG. 4B is a plot of the pH of pre-wash zone water, wash zone water,rinse zone water, and press water in a second washing system accordingto some implementations of the present disclosure.

While the present disclosure is susceptible to various modifications andalternative forms, specific embodiments and implementations are shown byway of example in the drawings and are described in detail herein. Itshould be understood, however, that the disclosure is not intended to belimited to the particular forms disclosed. Rather, the disclosure is tocover all modifications, equivalents and alternatives falling within thespirit and scope of the disclosure.

DETAILED DESCRIPTION

Referring to FIG. 1, a washing system 100 includes a housing 102, acontroller 108, a fresh water reservoir or tank 150, a chemicalreservoir or tank 154, a drain line 160, and a recirculation line 170.Generally, the washing system 100 is used for performing one or morewash sessions to clean soiled laundry (e.g., clothes, linens, fabrics,or the like).

A loading hopper or inlet (not shown) of the housing 102 receives soiledlaundry to be cleaned during a given wash session, and can be aresidential washer or a commercial tunnel washer (e.g., FIG. 2). Asshown, the housing 102 includes a fluid inlet 104 and a fluid outlet106. The fluid inlet 104 is coupled to the fresh water reservoir or tank150 and the chemical reservoir or tank 154 (e.g., via a metal pipe, aPVC pipe, a hose, or the like) such that the housing 102 receives freshwater from the fresh water reservoir or tank 150 and chemicals from thechemical reservoir or tank 154 for use during the wash session. Thefluid inlet 104, the fresh water reservoir or tank 150, the chemicalreservoir or tank 154, or any combination thereof can include one ormore valves (not shown) for use in controlling the volume of fresh waterand/or chemicals that flow into the housing 102. The chemical reservoiror tank 154 stores one or more chemicals for use during the washsession, such as, for example, detergent, bleach, alkalis, sours,solvents, hydrogen peroxide, paracetic acid, mineral spirits, or thelike, or any combination thereof.

Each wash session includes one or more cycles, including, for example, apre-wash cycle 110, a main wash cycle 120, a rinse cycle 130, andpress/spin cycle 140. At the beginning of each of the one or morecycles, the housing 102 receives fresh water from the fresh waterreservoir or tank 150 and/or chemicals from the chemical reservoir ortank 154 via the fluid inlet 104 (collectively, “wash water”). The washwater contacts the soiled laundry in the housing 102 for a predeterminedcycle time (e.g., between about one minute and about sixty minutes,between about three minutes and about six minutes, between about sixminutes and about twelve minutes, between about five minutes and aboutten minutes, etc.). In some implementations, the housing 102 rotates oroscillates to agitate the soiled laundry to mix the soiled laundry withthe wash water.

More specifically, the optional pre-wash cycle 110 is used to removelarge debris from the soiled laundry prior to the main wash cycle 120.During the main wash cycle 120, chemicals are used to clean the soiledlaundry (e.g., remove debris, dirt, stains and at least partiallysanitize). Fresh water and/or chemicals are then used during the rinsecycle 130 to remove residual wash water from the main wash cycle 120 andthe optional pre-wash cycle 110. During the optional press/spin cycle140, excess water from the rinse cycle 130 is removed from the cleanedlaundry to reduce the required drying time. The excess water can beremoved during the optional press/spin cycle 140 by pressing orcompressing the cleaned laundry to expel the excess water, or byspinning the cleaned laundry to create centrifugal forces that expel theexcess water.

Soiled wash water is drained from the housing 102 via the fluid outlet106. The soiled wash water can be drained before each of the cycles ofthe wash session, during each of the cycles of the wash session, aftereach of the cycles of the wash session, or any combination thereof. Thedrain line 160 is coupled to the fluid outlet 106, receives the soiledwash water, and delivers the soiled wash water to a main drain 164(e.g., a sewage or waste water line). The drain line 160 includes adrain valve 162 upstream of the main drain 164 that is coupled to therecirculation line 170. Instead of permitting all of the soiled washwater in the drain line 160 to flow into the main drain 164, the drainvalve 162 selectively diverts a portion of the soiled wash waterreceived by the drain line 160 to the recirculation line 170 (e.g.,between about 30 percent and about 50 percent of the soiled waterreceived by the drain line 160).

The recirculation line 170 includes a pump 172, an integrated fluidsanitizer module 180, and an optional storage tank 174. A first end ofthe recirculation line 170 is coupled to the drain valve 162 and asecond end of the recirculation line 170 is coupled to the fluid inlet104 of the housing 102. As shown, the pump 172 is positioned upstream ofthe integrated fluid sanitizer module 180 and the fluid inlet 104 toforce the predetermined volume of the soiled water to flow through therecirculation line 170. The recirculation line 170 can be a metal pipe(e.g., copper, stainless steel, or the like), a PVC pipe, a hose, or thelike, or any combination thereof.

As shown in FIG. 2, the integrated fluid sanitizer module 180 isgenerally used to at least partially sanitize the soiled wash water inthe recirculation line 170 and includes an oxidative gas generator 182,a manifold 192, and a counter-flow mixer 194. The oxidative gasgenerator 182 is used to produce a volume of o-zone gas and includes afirst lamp housing 184 a and a second lamp housing 184 b. The first lamphousing 184 a includes a first gas inlet 186 a and a first ultra-violet(“UV”) lamp 188 a disposed therein. Similarly, the second lamp housing184 b includes a second gas inlet 186 b and a second UV lamp 188 bdisposed therein. The first and second gas inlets 186 a, 186 b permitambient air to enter each of the respective lamp housings 184 a, 184 band to flow past each respective UV lamp 188 a, 188 b. When powered by apower source (not shown), the first and second UV lamps 188 a, 188 bemit a wavelength of light between about 100 nm and about 500 nm.

When ambient air enters the first gas inlet 186 a and the second gasinlet 186 b and flows past the first UV lamp 188 a and the second UVlamp 188 b while both are emitting a wavelength of light of betweenabout 180 nm and about 260 nm (e.g., about 187 nm), the wavelength oflight breaks down oxygen molecules (O₂) from the ambient air into oxygenatoms (O). These oxygen atoms then react with other oxygen (O₂)molecules in the ambient air to produce the volume of o-zone gas (O₃molecules). O-zone is a pale blue gas with a distinctively pungent smelland is a powerful disinfectant, oxidant, and deodorizer.

In some implementations, the oxidative gas generator 182 can include anoptional fan (not shown) to aid in forcing ambient air through the gasinlet 186 to produce the volume of o-zone gas. While the oxidative gasgenerator 182 is shown as having two lamp housings 184 a and 184 b andtwo UV lamps 188 a and 188 b, the oxidative gas generator 182 caninclude any number of lamp housings and/or UV lamps (e.g., one UV lamp,four UV lamps, etc.). In other implementations, the integrated fluidsanitizer module 180 includes an oxidative gas generator that does notinclude a UV lamp and produces the volume of o-zone gas using any othersuitable mechanism (e.g., corona discharge). Alternatively, theintegrated fluid sanitizer module 180 can include an o-zone gas storagetank (not shown) filled with o-zone gas and/or an oxygen storage tank(not shown) filled with oxygen gas. In such implementations, the oxygenstorage tank can be used in conjunction with the oxidative gas generator182 described above to deliver oxygen gas through the first and secondgas inlets 186 a, 186 b to increase the production of o-zone gas.

Once produced by the oxidative gas generator 182, the volume of o-zoneis delivered to the manifold 192 via a gas delivery line 190. The gasdelivery line 190 can be a metal pipe, a PVC pipe, a hose, or the like,or any combination thereof. The manifold 192 can be a venturi injector(with or without a bypass manifold), a mixing valve, a diffuser, anaeration system, or the like, or any combination thereof. When thevolume of o-zone gas reaches the manifold 192, the volume of o-zone gasis mixed with and at least partially sanitizes the soiled wash water inthe recirculation line 170 as it flows through the manifold 192.

O-zone gas sanitizes by killing and/or inactivating microorganisms(e.g., bacteria, viruses, algae, mold, fungi, or the like), and can bemany times more effective than chemicals. For example, o-zone gas can beapproximately 150% more effective than chlorine and reacts over 3,000times faster. O-zone gas is also advantageous because its chemicalreactions do not leave any harmful byproducts. Because of its highoxidation potential, o-zone gas can precipitate a variety of organic andinorganic contaminates, including, for example, iron, manganese,sulfides, metals, body oils, sweat, and saliva. Further, o-zone gasoxidizes organic chemicals that are responsible for producingundesirable odors.

Advanced oxidative processes (often referred to as “AOP's”) are a set ofchemical treatment procedures designed to remove organic and/orinorganic materials in water using hydroxyl radicals (*OH). Generally,the chemistry in AOP's can be divided into three parts: (1) formation ofhydroxyl radicals, (2) initial attacks by the hydroxyl radicals ontarget molecules, breaking the target molecules into fragments, and (3)subsequent attacks by hydroxyl radicals until ultimate mineralization.One subset of AOP chemical processes that produce hydroxyl radicalsemploys o-zone gas. First, o-zone gas (O₃) reacts with a hydroxyl ion(HO⁻) to yield HO₂ ⁻ and O₂ (oxygen). Next, a second o-zone molecule(O₃) reacts with the HO₂ ⁻ produced in the previous step to yield HO₂and O₃ ⁻ (an ozonide radical). The ozonide radical (O₃ ⁻) then reactswith H⁺ to yield HO₃ ⁻. Finally, the HO₃ ⁻ produced during the previousstep yields a hydrogen radical (*OH) and an oxygen molecule (O₂) uponprotonation.

The hydroxyl radical is often referred to as the “detergent” of thetroposphere because it reacts with many pollutants, decomposing themthrough “cracking”, often acting as the first step to their removal. Italso has an important role in eliminating some greenhouse gases likemethane and ozone. The rate of reaction with the hydroxyl radical oftendetermines how long many pollutants last in the atmosphere, if they donot undergo photolysis or are rained out. For instance methane, whichreacts relatively slowly with hydroxyl radical, has an average lifetimeof less than five years, and many CFCs have lifetimes of 50 years ormore. Pollutants, such as larger hydrocarbons, can have very shortaverage lifetimes of less than a few hours. The hydroxyl radicals firstreaction with many volatile organic compounds (often referred to as“VOC's”) having a chemical formula of RH, is the removal of a hydrogenatom, forming water (H₂O) and an alkyl radical (R*). The alkyl radicalwill typically react rapidly with oxygen (O₂) forming a peroxy radical(RO*2). The fate of this radical in the troposphere is dependent onfactors such as the amount of sunlight, pollution in the atmosphere andthe nature of the alkyl radical that formed it.

AOP's that form hydroxyl radicals are advantageous in the field of watertreatment for a number of reasons. For example, hydroxyl radicals caneffectively eliminate organic compounds in aqueous phase, rather thancollecting or transferred pollutants into another phase. Due to the highreactivity of hydroxyl radicals, they react with almost every aqueouspollutant without discriminating, thereby allowing many organiccontaminates to be removed at the same time. Hydroxyl radicals can alsoremove some heavy metals in the form of precipitated M(OH)_(x). Becausethe complete reduction product of hydroxyl radicals is H₂O, AOP's do notintroduce any new hazardous substances into the water.

As shown in FIG. 2, the counter-flow mixer 194 of the integral fluidsanitizer module 180 is positioned downstream of the manifold 192. Thecounter-flow mixer 194 includes a first portion 194 a and a secondportion 194 b positioned downstream of the first portion 194 a. Due tothis geometry, water in the recirculation line 170 flows into the firstportion 194 a and then into the second portion 194 b. The first portion194 a includes a first sanitizing lamp 196 a disposed therein and thesecond portion 194 b includes a second sanitizing lamp 196 b disposedtherein. When powered by a power source (not shown), the firstsanitizing lamp 196 a emits a first sanitizing wavelength of light andthe second sanitizing lamp 196 b emits a second sanitizing wavelength oflight. These sanitizing wavelengths of light kill and/or inactivatemicroorganisms and can range between about 10 nm and about 400 nm.Preferably, the first and second sanitizing wavelengths of light areabout 254 nm, which is commonly referred to as “germicidal ultra-violetlight”.

As water enters the first portion 194 a of the counter-flow mixer 194,the water flows past the first sanitizing lamp 196 a. The firstsanitizing wavelength of light emitted by the first sanitizing lamp 196a sanitizes the water by killing and/or inactivating microorganisms andreacts with the volume of o-zone gas injected in the manifold 192 toconvert O₃ molecules into hydroxyl radicals. The water then flows fromthe first portion 194 a into the second portion 194 b and flows past thesecond sanitizing lamp 196 b. Like the first sanitizing wavelength oflight, the second sanitizing wavelength of light emitted by the secondsanitizing lamp 196 b sanitizes the water and produces hydroxyl radicalsby reacting with O₃ molecules. The geometry and flow pattern of thecounter-flow mixer 194 causes press changes and turbulence in the waterto increase the chemical reactions between the o-zone gas, the water,and the sanitizing wavelengths of light emitted by the first and secondsanitizing lamps 196 a, 196 b. Sanitized water then exits the secondportion 194 b of the counter-flow mixer 194 and continues along therecirculation line 170 towards the optional storage tank 174 and thefluid inlet 104 (FIG. 1).

While the counter-flow mixer 194 is shown and described herein asincluding a first sanitizing lamp 196 a and a second sanitizing lamp 196b, the counter-flow mixer 194 can include any number of sanitizing lamps(e.g., one sanitizing lamp, four sanitizing lamps, ten sanitizing lamps,etc.). In some implementations, the integrated fluid sanitizer module180 does not include a counter-flow mixer and instead includes one ormore sanitizing lamps at least partially disposed within therecirculation line 170.

In some implementations, the integrated fluid sanitizer module 180includes a chemical feed line (not shown) that is coupled to thechemical reservoir or tank 154. The chemical feed line deliverschemicals into the recirculation line 170 to further aid in sanitizingthe soiled wash water. The chemical feed line of the integrated fluidsanitizer module 180 can include one or more pumps (not shown) and/orvalves (not shown) to control the flow of chemicals into therecirculation line 170. For example, the chemical feed line can deliverhydrogen peroxide into the recirculation line 170 (e.g., upstream of themanifold 192 and/or the counter-flow mixer 194). Hydrogen peroxide,which has a chemical formula of H₂O₂, is the simplest peroxide (i.e., acompound with an oxygen-oxygen single bond) and is often used as a weakoxidizer, bleaching agent, and disinfectant. For safety reasons,hydrogen peroxide is often handled as a dilute solution, rather than inits pure form.

In addition to producing hydroxyl radicals using o-zone gas, AOP's canemploy hydrogen peroxide and ultra-violet light to produce hydroxylradicals. When exposed to a wavelength of ultra-violet light (e.g.,light having a wavelength between about 150 nm and about 250 nm),hydrogen peroxide yields hydroxyl radicals, which as described above,act as a sanitizing agent. Specifically, the ultra-violet wavelength oflight causes hemolytic bond cleavage of the oxygen bond of one H₂O₂,molecule, resulting in the formation of two hydroxyl radicals. In thismanner, injecting hydrogen peroxide into the recirculation line 170 suchthat it is exposed to the sanitizing wavelengths of light of the firstand second sanitizing lamps 196 a, 196 b can force an AOP and producehydroxyl radicals. Further, as described above, hydrogen peroxide is oneof the chemicals that can be used in the one or more wash cycles (e.g.,during the main wash cycle 120) as a bleaching agent and/ordisinfectant. Thus, hydrogen peroxide may already be present in thesoiled wash water in the recirculation line 170 and can force additionalAOP's to Referring to FIG. 1, sanitized water in the recirculation line170 downstream of the integrated fluid sanitizer module 180 is deliveredto the fluid inlet 104 of the housing 102 by use of the pump 172, or oneor more additional pumps (not shown) for use in the wash session. Inthis manner, soiled wash water from any one of the one or more washcycles can be sanitized and reused in a different one of the one or morewash cycles of the same wash session. For example, the recirculationline 170 can receive soiled wash water via the drain line 160 and drainvalve 162 subsequent to the optional pre-wash cycle 110, sanitize thesoiled wash water using the integrated fluid sanitizer module 180, anddeliver sanitized water to the fluid inlet 104 for use during the mainwash cycle 120, the rinse cycle 130, or the optional press/spin cycle140. Likewise, the recirculation line 170 can receive soiled wash watervia the drain line 160 and drain valve 162 subsequent to the main washcycle 120, sanitize the soiled wash water using the integrated fluidsanitizer module 180, and deliver sanitized water to the fluid inlet 104for use during the rinse cycle 130 or the optional press/spin cycle 140.In addition, the recirculation line 170 can receive soiled wash watervia the drain line 160 and drain valve 162 subsequent to the rinse cycle130, sanitize the soiled wash water using the integrated fluid sanitizermodule 180, and deliver sanitized water to the fluid inlet 104 for useduring the optional press/spin cycle 140.

In some implementations, the recirculation line 170 includes an optionalstorage tank 174 positioned downstream of the integrated fluid sanitizermodule 180 that receives and stores the sanitized water from theintegrated fluid sanitizer module 180. In such implementations, thesanitized water can be delivered from the optional storage tank 174 tothe fluid inlet 104 of the housing 102 for use in the wash session or asecond wash session. For example, the recirculation line 170 can receivesoiled wash water subsequent to the optional press/spin cycle via thedrain line 160 and drain valve 162, sanitize the soiled wash water usingthe integrated fluid sanitizer module 180, and deliver sanitized waterto the optional storage tank 174 for use during for use during any oneof the one or more cycles of a second wash session (e.g., a rinse cycleof the second wash session). As described above, hydrogen peroxide canbe delivered by the chemical reservoir or tank 154 during one of the oneor more wash cycles of the wash session. When sanitized water isdelivered back into the housing 102 from the recirculation line 170, aresidual volume of o-zone gas remains in the sanitized water. Thus, theresidual o-zone gas reacts with the hydrogen peroxide used during, forexample, the rinse cycle 130 to produce hydroxyl radicals that can clean(e.g., whiten and brighten) the laundry.

The controller 108 is generally used to control the operation of thevarious elements of the washing system 100 and includes one or moreprocessors and an associated memory device for storing instructions thatare executable by the one or more processors. The controller 108 alsoincludes a communication module that is communicatively coupled (e.g.,by a wireless connection and/or a wired connection) to the variouscomponents of the washing system 100, such as the fluid inlet 104, thefluid outlet 106, the drain valve 162, the pump 172, the integral fluidsanitizer module 180, the optional storage tank 174, the fresh waterreservoir or tank 150, the chemical reservoir or tank 154, or anycombination thereof. The controller 108 can also include a human-machineinterface (“HMI”), such as a touchscreen interface, to permit a user tocontrol the various components of the washing system 100. For example,the HMI of the controller 108 can permit the user to select whether tooperate the optional pre-wash cycle 110 or the optional press/spin cycle140, to select the volume of wash water that the drain valve 162 divertsto the recirculation line 170, etc.

While the washing system 100 is shown as including all of the componentsdescribed above, more or fewer components can be included in a washingsystem. For example, an alternative washing system (not shown) includesthe housing 102, the drain line 160, and the recirculation line 170.Thus, various washing systems can be formed using any portion of thebasic components described herein.

Referring to FIG. 3, a tunnel washing system 200 that is similar to thewashing system 100 includes a wash tunnel 202, a press 240, a freshwater reservoir 250, a chemical reservoir 254, a first tank 260, asecond tank 264, a first recirculation line 270, a second recirculationline 272, a third recirculation line 273, an optional fourthrecirculation line 274, and an optional fifth recirculation line 275.The tunnel washing system 200 is generally used to efficiently cleanlarge volumes of soiled laundry.

The wash tunnel 202 includes a loading hopper 204, a helix that definesa plurality of modules 206, a first seal 208 a, a second seal 208 b, anda third seal 208 c. The helix is disposed within the wash tunnel 202 andhas a helix/cork-screw shape which defines the plurality of modules 206.The first seal 208 a, the second seal 208 b, and the third seal 208 care positioned within the wash tunnel 202 such that the first seal 208 adefines a pre-wash zone 210, the first seal 208 a and the second seal208 b define a main wash zone 220, and the second seal 208 b and thethird seal 208 c define a rinse zone 230. As shown, the pre-wash zone210 includes modules 1, 2, and 3 of the plurality of modules 206, themain wash zone 220 includes modules 4, 5, 6, 7, 8, and 9 of theplurality of modules 206, and the rinse zone 230 includes modules 10,11, 12, 13, and 14 of the plurality of modules 206.

Each of the plurality of modules 206 includes perforations (not shown)to permit fluid to flow between adjacent modules within the pre-washzone 210, the main wash zone 220, and the rinse zone 230 (e.g., betweenmodule 1 and module 2). The seals 208 a, 208 b, and 208 c inhibit fluidfrom freely flowing between adjacent modules of the plurality of modules206 (e.g., between module 9 and module 10). More specifically, the firstseal 208 a inhibits fluid flow between the pre-wash zone 210 and themain wash zone 220, the second seal 208 b inhibits fluid flow betweenthe main wash zone 220 and the rinse zone 230, and the third seal 208 cinhibits fluid flow between the rinse zone 230 and the press 240. As aresult, fluid flows through the plurality of modules 206 along arrow Ain the main wash zone 220, and fluid flows through the plurality ofmodules 206 along arrow B in the rinse zone 230.

To operate the tunnel washing system 200, soiled laundry is placed intothe wash tunnel 202 through the loading hopper 204 and falls into module1 of the plurality of modules 206 in the pre-wash zone 210. The helixoscillates back and forth within the wash tunnel 202 along a centralaxis to agitate the soiled laundry within the first module for apredetermined period (e.g., between about one minute and about twominutes). After the predetermined period, the helix rotates a fullrevolution about its central axis, and the soiled laundry is exchangedfrom module 1 to module 2 of the plurality of modules 206 through agenerally central throughhole of the helix. In this manner, the soiledlaundry moves through the plurality of modules 206 of the wash tunnel202 towards the press 240.

While the plurality of modules 206 of the wash tunnel 202 is shown ashaving fourteen modules, the plurality of modules 206 can have anynumber of modules based on the geometry of the helix (e.g., threemodules, ten modules, twenty modules, thirty modules, etc.). While notshown, the wash tunnel 202 can also include a finish zone positionedbetween the third seal 208 c and the press 240. The finish zone isgenerally used to administer a final treatment of water/chemicals to thelaundry prior to entering the press 240, and can comprise two modules ofthe plurality of modules 206.

The fresh water reservoir 250 is the same as, or similar to, the freshwater reservoir or tank 150 of the washing system 100 described aboveand includes a fresh water pump 251, a first fresh water valve 252 a, asecond fresh water valve 252 b, a third fresh water valve 252 c, afourth fresh water valve 252 d. The fresh water pump 251 pumps freshwater from the fresh water reservoir 250 towards the fresh water valves252 a, 252 b, 252 c, and 252 d. The chemical reservoir 254 is the sameas, or similar to, the chemical reservoir or tank 154 of the washingsystem 100 described above and includes a first chemical valve 256 a, asecond chemical valve 256 b, and a third chemical valve 256 c. Thechemical reservoir 254 can include a pump (not shown) that is the sameas, or similar to, the fresh water pump 251.

The first tank 260 includes a first tank feed line 262 that is coupledto the first fresh water valve 252 a and a first overflow line 263. Thefirst tank feed line 262 delivers fresh water from the fresh waterreservoir 250 to the first tank 260 for storage therein. The fresh waterpump 251 and the first fresh water valve 252 a control the volume offresh water that flows into the first tank 260 through the first tankfeed line 262. Similarly, the second tank 264, which is the same as, orsimilar to, the first tank 260, includes a second tank feed line 266that is the same as, or similar to, the first tank feed line 262 and iscoupled to the second fresh water valve 252 b. The second tank 264 alsoincludes a second overflow line 267. The first tank feed line 262 andthe second tank feed line 266 can be a metal pipe, a PVC pipe, a hose,or the like, or any combination thereof.

The pre-wash zone 210 of the wash tunnel 202 includes a pre-wash feedline 212 and a pre-wash chemical feed line 214. The pre-wash feed line212 is coupled to the first tank 260 and includes a pump 213. The pump213 pumps fluid stored in the first tank 260 (e.g., fresh waterdelivered by the first tank feed line 262 described above) through thepre-wash feed line 212 and into the pre-wash zone 210 (e.g., into theloading hopper 204 and/or module 1). The pre-wash chemical feed line 214is coupled to the first chemical valve 256 a of the chemical reservoir254 and delivers chemicals to the pre-wash zone 210 (e.g., into theloading hopper 204 and/or module 1). The chemicals delivered by thepre-wash chemical feed line 214 and the fluid delivered by the pre-washfeed line 212 mix to form pre-wash water that is then used in thepre-wash zone 210.

The main wash zone 220 of the wash tunnel 202 includes a main wash feedline 222 and a wash chemical feed line 224. The main wash feed line 222is coupled to the second tank 264 and includes a pump 223. The pump 223pumps fluid stored in the second tank 264 (e.g., fresh water deliveredby the second tank feed line 266 described above) through the main washfeed line 222 and into the main wash zone 220 (e.g., into module 9). Thewash chemical feed line 224 is coupled to the second chemical valve 256b of the chemical reservoir 254 and delivers chemicals into the pre-washzone 210 (e.g., into module 9). The chemicals delivered by the washchemical feed line 224 and the fluid delivered by the main wash feedline 222 mix to form wash water that is then used in the main wash zone220.

The rinse zone 230 of the wash tunnel 202 includes a fresh water feedline 232 and a rinse chemical feed line 234. The fresh water feed line232 is coupled to the third fresh water valve 252 c of the fresh waterreservoir 250 and delivers fresh water from the fresh water reservoir250 to the rinse zone 230 (e.g., into module 14). The rinse chemicalfeed line 234 is coupled to the third chemical valve 256 c of thechemical reservoir 254 and delivers chemicals into the rinse zone 230(e.g., into module 14). The chemicals delivered by the rinse chemicalfeed line 234 and the fresh water delivered by the fresh water feed line232 mix to form rinse water that is then used in the rinse zone 230.

As shown, the press 240 is positioned directly adjacent to the rinsezone 230 and includes a press water feed line 242 and a press water tank244. Laundry exits the rinse zone 230 of the wash tunnel 202 and entersthe press 240. The press 240 is generally used to remove excess rinsewater from the laundry prior to transporting the laundry to a dryer. Thepress 240 removes excess water by compressing or squeezing the laundryto expel excess water (“soiled press water”) using hydraulic mechanismsor the like. The press water feed line 242 is coupled to the fourthfresh water valve 252 d of the fresh water reservoir 250 and deliversfresh water from the fresh water reservoir 250 to the press 240. Thepress water tank 244 receives and stores the soiled press water andincludes a press water diversion valve 246.

The first recirculation line 270 is coupled to the press water diversionvalve 246 and includes a pump 270 a and an integrated fluid sanitizermodule 280. The first recirculation line 270 receives a portion of thesoiled press water from the press water tank 244 via the press waterdiversion valve 246. The integrated fluid sanitizer module 280 is thesame as or similar to the integrated fluid sanitizer module 180 of thewashing system 100 described above and is used to at least partiallysanitize the portion of the soiled press water received by the firstrecirculation line 270. The pump 270 a pumps the portion of the soiledpress water through the first recirculation line 270 and the integratedfluid sanitizer module 280 to the rinse zone 230 (e.g., as shown, intomodule 14). The first recirculation line 270 can be a metal pipe, a PVCpipe, a hose, or the like, or any combination thereof. In someimplementations, the first recirculation line 270 includes a storagetank (not shown) that is the same as or similar to the optional storagetank 174 of the washing system 100.

The second recirculation line 272 is similar to the first recirculationline 270 in that it is coupled to the press water diversion valve 246and includes a pump 272 a. The second recirculation line 272 receives asecond portion of the soiled press water from the press water tank 244via the press water diversion valve 246. The second recirculation line272 differs from the first recirculation line in that it is coupled tothe first tank 260, and the pump 272 a pumps the second portion of thesoiled press through the second recirculation line 272 to the first tank260. The second portion of the soiled press water mixes with the freshwater delivered to the first tank 260 via the first tank feed line 262.As described above, the pre-wash feed line 212 delivers fluid from thefirst tank 260 to the pre-wash zone 210, meaning that at least some ofthe second portion of the soiled press water received by the first tank260 is delivered to the pre-wash zone 210 via the pre-wash feed line212.

Like the first recirculation line, the second recirculation line 272 canbe a metal pipe, a PVC pipe, a hose, or the like, or any combinationthereof. While not shown, in some implementations, the secondrecirculation line can include a second integrated fluid sanitizermodule that is the same as or similar to the integrated fluid sanitizermodule 280 of the first recirculation line and the integrated fluidsanitizer module 180 of the washing system 100. In otherimplementations, the press tank can include an integrated fluidsanitizer module that is the same as or similar to the integrated fluidsanitizer module 280 that sanitizes the press water prior to beingdelivered to the first recirculation line 270 and/or secondrecirculation line 272.

The press water diversion valve 246 controls amount of soiled presswater that flows into either the first recirculation line 270 or thesecond recirculation line 272. For example, desirably, the press waterdiversion valve 246 diverts about thirty percent to about fifty percentof the soiled press water from the press water tank 244 to the firstrecirculation line 270 and about seventy percent to about thirty percentof the soiled press water from the press water tank 244 to the secondrecirculation line 272. Diverting about thirty percent to about fiftypercent of the soiled press water to the first recirculation line 270helps prevent the first tank 260 from overflowing due to the secondrecirculation line 272.

As described above, the rinse zone 230 uses rinse water which comprisesfresh water received via the fresh water feed line 232, chemicalsreceived via the rinse chemical feed line 234, and/or sanitized presswater received via the first recirculation line 270. As shown in FIG. 3and described above, the rinse water generally flows between module 14and module 10 along arrow B. The rinse zone 230 includes a rinse waterdrain 235 (often referred to as a “weir box”) to control the rinse waterlevel in the rinse zone 230 and to drain soiled rinse water that hasbeen contaminated by the laundry (e.g., rinse water that has flowed frommodule 14 to module 10). The rinse water drain 235 is coupled to a rinsedrain line 236 that receives the soiled rinse water. The rinse drainline 236 includes a lint screen 237 and a rinse water diversion valve238. As shown, the lint screen 237 is integral with the rinse drain line236 and is positioned upstream of the rinse water diversion valve 238.The lint screen 237 removes lint that has accumulated in the soiledrinse water from the laundry. The rinse drain line 236 continues pastthe rinse water diversion valve 238 and is coupled to a main drain 290that is the same as or similar to the main drain 164 of the washingsystem 100 (e.g., a sewage line).

The third recirculation line 273 is coupled to the rinse water diversionvalve 238 and includes a pump 273 a. The third recirculation line 273receives a portion of the soiled rinse water from the rinse drain line236 via the rinse water diversion valve 238. The third recirculationline 273 is also coupled to the second tank 264, and the pump 273 apumps the portion of the soiled rinse water through the thirdrecirculation line 273 to the second tank 264. The portion of the soiledrinse water then mixes with the fresh water delivered to the second tank264 via the second tank feed line 266. As described above, the main washfeed line 222 delivers fluid from the second tank 264 to the main washzone 220. As a result, at least some of the portion of the soiled rinsewater received by the second tank 264 is delivered to the main wash zone220 via the main wash feed line 222.

The third recirculation line 273 is the same as or similar to the firstand second recirculation lines 270, 272 in that the third recirculationline 273 can be a metal pipe, a PVC pipe, a hose, or the like, or anycombination thereof, and can include an integrated fluid sanitizermodule (not shown) that is the same as or similar to the integratedfluid sanitizer module 280. Alternatively, the rinse drain line 236 caninclude an integrated fluid sanitizer module that is the same as orsimilar to the integrated fluid sanitizer module 280 and sanitizes thesoiled rinse water upstream of the rinse water diversion valve 238.

In some implementations, the tunnel washing system 200 includes theoptional fourth recirculation line 274, which is coupled to the rinsewater diversion valve 238 and includes a pump 274 a. The optional fourthrecirculation line 274 is similar to the third recirculation line 273 inthat it is coupled to the rinse water diversion valve 238 and receives asecond portion of the soiled rinse water from the rinse drain line 236.More specifically, in such implementations, the rinse water diversionvalve 238 is a four-way valve that is used to control the respectivevolumes of the portion of the soiled rinse water received by the thirdrecirculation line 273, the second portion of the soiled rinse waterreceived by the optional fourth recirculation line 274, and a thirdportion of the soiled rinse water received by the main drain 290. Asshown, the optional fourth recirculation line 274 is connected to firstrecirculation line 270 so that second portion of the soiled rinse waterflows through the integrated fluid sanitizer module 280 and issanitized. As described above, the first recirculation line 270 deliversfluid from the integrated fluid sanitizer module 280, thus, in suchimplementations, the first recirculation line 270 delivers sanitizedrinse water to the rinse zone 230 (e.g., into module 14). Alternatively,the optional fourth recirculation line 274 can include a fourthintegrated fluid sanitizer module (not shown) that is the same as orsimilar to the integrated fluid sanitizer module 280, and the fourthrecirculation line directly delivers sanitized rinse water to the rinsezone 230.

As described above, the main wash zone 220 uses wash water whichcomprises fluid from the first tank 260 received via the main wash feedline 222 and/or chemicals received via the wash chemical feed line 224.As shown in FIG. 3 and described above, the wash water generally flowsbetween module 9 and module 4 along arrow A. The main wash zone 220includes a wash water drain 225 (often referred to as a “weir box”) tocontrol the wash water level in the main wash zone 220 and to drainsoiled wash water (e.g., wash water that has flowed from module 9 tomodule 4 and has become contaminated by the soiled laundry). The washwater drain 225 is coupled to a wash water drain line 226 that receivesthe soiled wash water and has a wash water diversion valve 228. The washwater drain line 226 continues downstream of the wash water diversionvalve 228 and is coupled to the main drain 290. As shown, the overflowline 263 of the first tank 260 and the overflow line 267 of the secondtank 264 are coupled to the wash water drain line 226 downstream of thewash water diversion valve 228, permitting overflow from the first tank260 and/or second tank 264 to spill into the main drain 290 and exit thesystem.

In some implementations, the tunnel washing system 200 includes anoptional fifth recirculation line 275 that is coupled to the wash waterdiversion valve 228 and includes a pump 275 a. The optional fifthrecirculation line 275 is similar to the optional fourth recirculationline 274 in that it receives a second portion of the soiled wash waterfrom the wash water drain line 226 via the wash water diversion valve228. As shown, the optional fifth recirculation line 275 is coupled tothe first tank 260, and the pump 275 a pumps the second portion of thesoiled wash water through the fifth recirculation line 275 and into thefirst tank 260. As described above, the pre-wash feed line 212 deliversfluid from the first tank 260 to the pre-wash zone 210, thus, in suchimplementations, the pre-wash feed line 212 delivers at least a some ofthe second portion of soiled wash water stored in the first tank 260 tothe pre-wash zone 210.

In some implementations, the optional fifth recirculation line 275 caninclude an integrated fluid sanitizer that is the same as or similar tothe integrated fluid sanitizer module 280 of the first recirculationline 270 to sanitize the soiled wash water prior delivering it to thefirst tank 260. Further the fifth recirculation line 275 can be coupledto the pre-wash zone 210 (e.g., via the loading hopper 204) to directlydeliver soiled wash water to the pre-wash zone 210.

Referring generally to FIGS. 4A and 4B, the pH of the pre-wash water,the wash water, and the rinse water of a washing system can becontrolled to effectively clean soiled laundry. As shown, it isdesirable that the pH of the pre-wash zone water is between about 9 andabout 10.5, the pH of the main wash zone water is between about 10.5 andabout 7, and the pH of the rinse zone water and press water is betweenabout 5 and about 6. In other words, the pre-wash zone and a first halfof the main wash zone comprise a high alkalinity zone (i.e., high pH)and a second half of the main wash zone, the rinse zone, and the presscomprise a low alkalinity zone (i.e., low pH).

FIG. 4A shows the pH of pre-wash zone water, main wash zone water, rinsezone water, and press water of a first washing system that is similar tothe tunnel washing system 200 described above. The first washing systemdiffers from the tunnel washing system 200 in that it does not include afirst recirculation line, a fourth recirculation line, or a fifthrecirculation line. As described above, the pre-wash zone receives fluidfrom the first tank, which includes fresh water and soiled press water,meaning that the pH of the fluid delivered from the first tank to thepre-wash zone is about 6. To raise the pH of the pre-wash zone water tobe between about 10.5 and about 11, chemicals must be added to thepre-wash zone via a chemical feed line that is the same as or similar tothe pre-wash chemical feed line 214 described above. This requiredchange in pH in the pre-wash zone is illustrated by ΔpH₁ in FIG. 4A.Similarly, laundry enters into the rinse zone from the high alkalinityzone (i.e., with a high pH) saturated with wash water, and the rinsezone receives rinse water a fresh water feed line that is the same as orsimilar to the fresh water feed line 232 described above. Thus,chemicals (e.g., sours, parasitic acid, hydrogen peroxide, or any othersuitable chemical with a low pH) must be delivered to the rinse zone viaa chemical feed line that is the same as or similar to the rinsechemical feed line 234 to lower the pH of the rinse zone water to bebetween about 5 and about 6. The required change in pH in the rinse zoneis illustrated by ΔpH₂ in FIG. 4A.

FIG. 4B shows the pH the pre-wash zone water, main wash zone water,rinse zone water, and press water of a second washing system that issimilar to the first washing system and the tunnel washing system 200described above. The first washing system differs from the first washingsystem in that it includes a first recirculation line that is the sameas or similar to the first recirculation line 270 of the tunnel washingsystem 200 and a fifth recirculation line that is the same as or similarto the optional fifth recirculation line 275 of the tunnel washingsystem 200. The fifth recirculation line delivers soiled wash water,which has a pH of between about 10.5 and about 11, to the first tank. Asa result, the pH of the fluid in the first tank is raised to about 9.5prior to being delivered to the pre-wash zone, meaning that the requiredchange in pH at the beginning of the pre-wash zone denoted by ΔpH₃ issubstantially less than ΔpH₁ in FIG. 4A for the first washing system.Similarly, the first recirculation line delivers sanitized press waterto the rinse zone having a pH of between about 5 and about 6. Thus, therequired change in pH in the rinse zone, which is denoted by ΔpH₄, issubstantially less than ΔpH₃ in FIG. 4A for the first washing system. Inother words, fewer chemicals are required to obtain the desired pH levelin the pre-wash zone and in the rinse zone, reducing the costs tooperate the second washing system as compared to the first washingsystem.

While the integrated fluid sanitizer modules 180, 280 have beendescribed herein as being used in a recirculation line (e.g.,recirculation line 170), the integrated fluid sanitizer modules can beused in other portions of the wash systems 100, 200. For example, thewash water drain line 226 can include an integrated fluid sanitizermodule that is the same as, or similar to, the integrated fluidsanitizer 180. In such implementations, soiled water wash is at leastpartially sanitized by the integrated fluid sanitizer module prior tobeing discharged into the main drain 290 (e.g., a sewage line).

EXAMPLES

In one example, a washing system that is similar to the washing systems100 and 200 described above in that it includes an integrated fluidsanitizer module (e.g., the integrated fluid sanitizer module 180 shownin FIG. 2). The water in this washing system was tested to demonstratethe reduction in bacteria in the water after passing through theintegrated fluid sanitizer module. Table 1 shows the test results incolony-forming units per milliliter (“CFU”):

TABLE 1 Pre-Aerobic Plate Pre-Aerobic Count of Water Plate Count ofPre-treatment Water Post-treatment Method Test #1 37 CFU/mL 3 CFU/mL SM9215B 20^(th) Ed. Test #2 73 CFU/mL 8 CFU/mL SM 9215B 20^(th) Ed.

As indicated by the test results in Table 1, the integrated fluidsanitizer caused a 99.92% reduction in bacteria in Test #1 and a 99.89%reduction in bacteria in Test #2 (using a logarithmic scale reduction).For water to be considered potable (i.e., drinkable), the Safe DrinkingWater Act currently requires the Maximum Contaminant Level (“MCL”) ofmicroorganisms to be below 200 MCL.

To further demonstrate that the integrated fluid sanitizer modulecontinuously disinfects water as it recirculates through the washingsystem multiple times, a second test was completed to measure thecontaminates before and after a first recirculation loop, and before andafter a second recirculation loop. Table 2 below summarizes the results:

TABLE 2 Pre-Aerobic Plate Count of Water at Beginning Pre-Aerobic PlateCount of Loop of Water at End of Loop Method Loop #1  7 CFU/mL  5 CFU/mLSM 9215B 20^(th) Ed. Loop #2 36 CFU/mL 21 CFU/mL SM 9215B 20^(th) Ed.

As indicated by the test results in Table 2, the integrated fluidsanitizer module continued to reduce bacteria in the water duringmultiple recirculation cycles in the washing system. Thus, theintegrated fluid sanitizer module can be used to at least partiallysanitize the same recirculation water multiple times.

While the disclosure is susceptible to various modifications andalternative forms, specific embodiments and methods thereof have beenshown by way of example in the drawings and are described in detailherein. It should be understood, however, that it is not intended tolimit the disclosure to the particular forms or methods disclosed, but,to the contrary, the intention is to cover all modifications,equivalents and alternatives falling within the spirit and scope of thedisclosure.

What is claimed is:
 1. A tunnel washing system comprising: a housingincluding a pre-wash zone, a main wash zone, and a rinse zone, the mainwash zone having a first fluid inlet and a first fluid outlet and therinse zone having a second fluid inlet and a second fluid outlet; apress coupled to a press tank, the press tank being configured toreceive and store therein soiled press water; and a recirculation linecoupled to the press tank and configured to receive a portion of thesoiled press water, the recirculation line including an integrated fluidsanitizer module configured to at least partially sanitize the portionof the soiled press water, the recirculation line being coupled to thesecond fluid inlet of the rinse zone to deliver the at least partiallysanitized water to a module of the rinse zone.
 2. The washing system ofclaim 1, wherein the sanitized press water delivered into the rinse zonehas a pH that is between about 5 and about
 6. 3. The washing system ofclaim 1, wherein the integrated fluid sanitizer module includes amanifold and an oxidative gas generator configured to deliver a volumeof o-zone gas to the manifold, wherein the volume of o-zone gas reactswith the portion of the soiled water received by the recirculation lineto produce peroxone, hydroxyl radicals, or both to aid in sanitizing theportion of the soiled water.
 4. The washing system of claim 3, whereinthe oxidative gas generator includes an ultra-violet (“UV”) lampconfigured to emit a wavelength of light to react with ambient air andproduce the volume of o-zone gas.
 5. The washing system of claim 1,wherein the integrated fluid sanitizer module includes a germicidalultra-violet (“UV”) lamp configured to emit a sanitizing wavelength oflight to aid in sanitizing the portion of the soiled water.
 6. Thewashing system of claim 1, wherein the integrated fluid sanitizer moduleincludes a manifold, an oxidative gas generator, and a germicidal UVlamp, the oxidative gas generator being configured to deliver a volumeof o-zone gas to the manifold, the germicidal UV lamp being positioneddownstream of the manifold and being configured to emit a sanitizingwavelength of light.
 7. The washing system of claim 1, furthercomprising: a press drain line coupled to the press tank and configuredto receive a second portion of the soiled press water, wherein theportion of the soiled press water received by the recirculation line isless than or equal to the second portion of the soiled press water thatis received by the press drain line.
 8. The washing system of claim 7,further comprising: a first tank including a third fluid inlet and athird fluid outlet, the third fluid inlet being coupled to the pressdrain line and a fresh water reservoir, the first tank being configuredto receive and store the second portion of the soiled press water, freshwater, or both therein; and a prewash feed line coupled to the fluidoutlet of the first tank and a fourth fluid inlet of the pre-wash zoneand is configured to deliver soiled press water, fresh water, or bothinto the pre-wash zone.
 9. The washing system of claim 8, furthercomprising: a second recirculation line coupled to the first fluidoutlet of the main wash zone and the third fluid inlet of the first, thesecond recirculation line being configured to receive soiled wash waterfrom the main wash zone and deliver a portion of the soiled wash waterinto the first tank.
 10. The washing system of claim 9, wherein thesecond recirculation line includes a second integrated fluid sanitizedmodule configured to at least partially sanitize the soiled wash waterreceived by the second recirculation line.
 11. The washing system ofclaim 8, wherein the portion of the soiled press water received by therecirculation line is between about 30 percent and about 50 percent ofthe soiled press water received by the press tank and the second portionof the soiled press water received by the press drain line is betweenabout 70 percent and about 50 percent of the soiled press water receivedby the press tank.